How To Make Polyurethane Foam | How Foam Is Made In A Factory?
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- เผยแพร่เมื่อ 17 ต.ค. 2024
- How to Make Polyurethane Foam |
How Foam Is Made In a Factory?
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Polyurethane foam is used primarily for bedding and furniture stuffing.
Isocyanates and Polyols
In the foaming, the two most common isocyanates are TDI (for flexible and semi-rigid foaming) and MDI (for rigid foaming).
TDI + polyol has made polyurethane polymer, which now can be expanded to make foam. To do that, we add water. Isocyanate is highly reactive, and produces two things with water: urea linkages/urethane, and carbon dioxide (CO2) gas.
Blowing the Foam
The CO2 is considered primary blowing agent. As a gas, it blows little air pockets into the PU to form the foam. Just like blowing soap bubbles though, there is a point when the liquid casing cannot withstand the pressure of the air inside and bursts.
To successfully make material foam, the polyurethane must gel into shape once air has been blown to it. It’s harder than it sounds, and it’s also why foam technicians can make or break your factory production. The art of foam-making revolves around this sensitive balance between expansion, or blowing, and gelling.
Once they’re formed inside the polyurethane, we’re going to call the air bubbles cells. If the foam expands and gels before any air bubbles burst, you get closed-cell foams, which are semi-rigid (not truly rigid like foam made of MDI) since the material doesn’t bend as easily. To go back to our ladder metaphor, closed-cell foams are like wood ladders, whereas open-cell foams are like rope ladders. If some or all cell walls are allowed to rupture before gellation, you get a much more flexible material that bends, twists, and even breaks easier.
what is polyurethane foam? Basically: TDI, polyol, water, polymer, open versus closed-cell.
Additives.
see PU foaming additives by function. One of the most important additives is the catalyst, which can affect the basic reactions in several ways. It can speed the expansion, speed the gelling, cool the reaction (so you have less of a fire hazard on your hands), etc. There are also curing agents, which include chain-extenders and cross-linking agents. Chain-extenders, like their name suggests, extend polymer chains, which increases material flexibility. Cross-linking agents promote and strengthen cross-linkages, increasing structural integrity for more rigid foams.
Think of surfactants like emulsifiers. Oil and water on their own do not mix, but once you add some dish soap, they can be emulsified into a uniform mixture. Surfactants work like the soap. A more uniform mixture means a smoother reaction, and you get more even cell sizes, steadier reaction speeds, and finer control between gellation and foam collapse.
(The reason they’re called surfactants is because they reduce the surface, or interface tensions between two compounds. As in, the oil doesn’t just sit neatly on top of the water surfactants blend that interfacing surface between them.)
PU Foaming Chemistry oil
Remember that CO2 gas from the reaction with water acts as a blowing agent? other blowing agents may also be used or added. The main inconvenience of water blowing is the high temperature of the reaction, making PU foaming a fire hazard. Physical blowing agents (additives that physically encourage the expansion of cells instead of that initial CO2, which is chemically blown) reduce that fire hazard.
A similar additives is fillers. They come as particles or fibers. Particulate fillers can reduce flammability and add weight to foam (good for cushioning foams). Fibrous fillers reinforce cell structure. All fillers function to 1) add physical properties like tensile or compressive strength to foam, and 2) save on costs by reducing the amount of liquid chemicals used per batch.
The main ingredients are.
Isocyanate: TDI
Polyol: polyol
Blowing Agents: water, methylene-chloride (MC)
Catalysts: amine, tin
Surfactant: silicone
Now we understand what each element does during the foaming process. TDI + polyol begins the creation of polyurethane. A mixing head first injects small amounts of air into the liquid mix to kickstart the foaming process. TDI + water chemically produces the CO2 gas that blows the liquid into foam. In addition, we add MC so that less water is used in the initial reaction and the overall reaction temperature is lower, all while cell expansion is retained.
Meanwhile, the amine additive is doing multi-purpose catalysis (speeding the reaction) and tin provides a stable gelling catalyst, increasing foam structural elasticity. Silicone smooths and steadies the entire blowing process, maintaining cell structure evenness until gellation occurs.
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Your videos on PU foam making are very good and informative. This has given us a lot of information. But if a few things are added to it, it will become much better and more informative.
. The name of the chemical and its quantity should be mentioned in its screen shot
. What is the role of the chemical [Polyol, Polymer Polyol,Calcium Carbonate,SO,Water,Silicone,Amin,MCL,TDI ] used in the foam? And what does it matter if they are "less" or "more". such as [water Increasing the amount of water decreases the density of the foam and decreasing the amount of water increases the density of the foam.
Because water is a boiling agent and so is gas is formed which swells the foam.]
Watch my other video everything is available there
How much will it cost to set up this machine completely (Round figure) please 🙏🙏🙏
Watch part 10
th-cam.com/video/CNv4k_hDg_k/w-d-xo.html
Sir 32 dencity k liye kitni kitni qty m chemical dalna h
Next video me full information milegi
Please jorhat could i know the density u made ? And english translation please
Bahut hi Achcha video banaya hai sir
🙏
Can i make normal matress by this formula?
Yes
Sir how can I calculate by myself please give me formula
@Maira-hs3tu next video
@@pufoambysss1 when will u upload it
Sir iskmy cemicals ki quantity kitni kitni use karni hai????
Density ke anusar
agar ye foam ka liquid ko kisi compress jagah me yani hoti jagah me to kya hoga ,
yani agar kisi bottle me bhardiya or uska zakkan laga diya to kaisa foam banega
Super
Is block ka kya size h
Foam delivery hoga
Very informative video I am from pakistan I am interested in PU making process and need ur help. My family also migrated from haryana district Rohtak
Good
7567607049
Do you give coaching sir?
Yes my WhatsApp no. 7567607049
Chemical sa wait number bolo sir konsa chemical kitna wait raigina Or kitna wait me kitna foam hoga
OK next video
Sir SO chemical ka full form kya hai
Satnnous Octoate
Thank you sir information ke liye,🙏💐
my brother can get English translation please if possible
2gud sir👌🙏🏻
Very good video sir
Good information bro
Or bhi bnaye asi video 🙏
Bana liya to sale ki problem to nhi hogi
Nhi ji
formula de skte ho kya?
Next Video me
@@pufoambysss1 konsa chemical kitna dalna...or alg alg density ke liye kitna ye konse part me hai..
Market me demand hai pu foam ki
Ji ha
LD 5 density formula bataiye
bro aapka nmnr mil skta he me.kuwait me puf machine operate kr rha hu
Super
Good video bro
Thanks brother
Thanks
Very good
I do not understand but I am happy you are using an breathing protection
Thank you 🙏
TDI and calcium carbonate is same?
No
Nice information!
🙏
3rd video pliz n thanks for your help
allredy in my channel
Please mention ratio
What is the name of third component?
Watching the video again
Sound naheya vai
14 mm how much price
WhatsApp only 7567607049
Dear brother, please provide me with an English translation if possible .
Oknsir part 4 in English
💖💖💖welldoe💖💖💖
Pakistan
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Tamilnadu se baat karte hain office phone karo hamen yah duster line karte hain iska hamna kya thoda kam Idea yah video aapka dekha bahut pasand aaya hai kidhar kuchh plan lagate Hain kya aap Aakar lagaye to humko Jara training de diye sar iska jawab WhatsApp mein kar dijiye sar
7567607049 WhatsApp only
@@pufoambysss1 hi
Hallo ji kse ho bro
Sir send mee parsanal na. Plz
WhatsApp only sir 7567607049
Buenos dias exelente video porfabor me podria ayudar en la formulacion qe insumos utiliso y deqe dencidad ellaboro porfabor nos podemos contactar por wasat gracias
WhatsApp only 7567607049
my brother can get English translation please if possible
ok sir send me Hi on whatsapp i will send you english translation.
Watch part 4 in English
s o full form
Can you translate to english
Hola me ayudas para mejorar mi fórmula
7567607049
@@pufoambysss1 tengo una fórmula para hacer una densidad de 18 pero se forma la espuma y luego de baja
@@pufoambysss1 para que sería ese número que sale en tu mensaje idioma español
Buenas noches, mejoraste tu formula
@@JoseVasquez-gw6sk hola no no la pude mejorar.. usted sabe cómo mejorarla??
Can get english translation please
Watching part 4 in English
Hello
7567607049
Please English
Watch part 3 & 4
Sir your whatsapp naber said me
Thanks
Welcome